S.O.

Concrete production facilities supplying concrete to Department projects shall have

adequate Construction Training and Qualification Program (CTQP) qualified personnel.
Batch Plant Operator, qualified technicians, Manager of Quality Control and driver are
required positions for an approved concrete production facility and shall be CTQP qualified.
At the discretion of the Department, certain functions of the above positions may be
combined when it can be demonstrated that the plant operation and quality of the concrete
will not be detrimentally affected. The qualification of any personnel shall be made available
upon request.

1. Materials Inspection and Acceptance:

The review of documentation and collection of samples will confirm the facility meets
all Malaysia standards, and is in compliance with all Materials and Tests policies.

2. Personnel should be aware at all times of functioning equipment and machinery.

Review all safety guidelines required by the facility. Safety Equipment List is safety
vest, safety helmet, safety boots, eye and ear protection and gloves for collecting
samples

3. M&T Inspector’s Audit:

Verify 3rd party facility certificate with expiration date is on site.

Verify 3rd party inspection report (complete report/check list performed by 3rd party)
is on-site.

Verify 3rd party inspector has been certified by Malaysia standard.

Verify facility manager is sending all 3rd party inspection documentation to M&T
(see Annual Facility Audit Field Book).

View and verify facility is utilizing Malaysia standard approved mix designs.
 View and verify certification of all on-site Malaysia standard Concrete Field
Technicians. Technician certifications must be active.

View and verify certification of all on-site Malaysia standard Concrete Batch
Technicians. Technician certifications must be active.

View and verify approved materials (cement, fly ash, aggregate, admixtures) per
approved mix designs.

View and verify on-site approved trucks (new list is to be generated every year- kept
onsite).

Verify documentation regarding the performance of moisture tests on fine and coarse
aggregates.

Verify the Certified on-site Batching Technician has the ability to adjust moisture
during the batching process (review of batch tickets and/or operating process is
acceptable).

View sample of associated Malaysia standard documentation (903, 250, copies of

batch weights, etc) is completed for every Malaysia standard production of concrete.

4. Batch Plant Operator

Personnel who have quality control functions or who sign concrete delivery tickets
must demonstrate, through examination, adequate concrete related knowledge. Batch
Plant Operator/s shall be present during batching operations. The Plant Operator shall
be qualified by CIDB or an equivalent training program.
Planning

1. Batching plant location

2. Concreting platform location

The first given by the manufacturer in accordance with the concrete batch Plant
installation foundation plans, and prepare the ground and embedded. Installed base
must be solid, consistent architectural design specifications.

Assembly concrete batch Plants hoisting equipment, such as cranes, tower vehicles,
the installation process is not only to choose the right position, the more important is
that we must use professional operators to install.

3. Enter access and road

Good planning construction of access roads, temporary showing concrete placing

booms bridge, wharf and stockpiling area, and undertake levelling, not only did water,
electricity, land levelling.
Cost

1. The ready mix concrete plant setup cost are designed for ready-mix producers,
contractors, precast manufacturers and special applications. Standard models
furnished with Twin Shaft Mixers from 1.0 m3 up to 6.0 m3 compacted output per
batch.

2. The ready mix concrete plant setup cost are available in various capacities ranging
from 20 m3, to 35 m3 per hour of compacted concrete output and designed for
operations under extreme conditions with highest performance. The rent cost for 2
years is RM202,245.

3. The ready mix concrete plant need to setup on 3750m2 platform with course
aggregate storage, fine aggregate storage, washing bay, access road, test area and
batching area. The cost for concrete platform is RM15000.
Safety and maintenance

1. Safety procedure is the important matter when in batching plant. Operator and
workers must careful and alert with hazard, flammable fuel, electric shock, manual
handling hazards, exhaust fumes and skin (membrane) irritation from cement or
additives.

2. Protective equipment & emergency equipment must always use such as safety glasses
and hearing protection, electrical safety equipment and protective footwear, protective
clothing and appropriate gloves

3. Batching plant need to inspect at all areas, including bearings, belts and the air system
and filters. Also inspect that the blades in the concrete batching plant are fitted firmly
and that all pipes are secure. Always make sure that all electrical devices are
operational. Make sure you keep the necessary areas lubricated with oil, such as the
seals of the shaft ends. Fix any minor problems. If you notice loose bearings, these
should be replaced straight away to prevent a breakdown and the resultant production
delay as well as the costly repairs that will need to be performed on the plant. Keep
stock of all replaceable parts for your concrete batching plant. By keeping these
materials close-at-hand, replacing any damaged parts will not require waiting for the
parts. In this way, you can ensure that it is always operational. Keep your concrete
batching plant clean. By keeping it free of dust, you can significantly reduce wear and
tear on your plant. Be sure to drain all pipes of any liquid after each use.

https://connect.ncdot.gov/resources/Materials/MaterialsResources/SOP_ready%20mix%20an
nual%20facility%20audit.pdf